Timing Belt Covers — Removal and Installation (Opel Omega B2)

Outer cover

Caution: New water pump and power steering pump pulley mounting bolts will be required during installation.

Removal

1. Remove the multi-chamber air intake system accumulator assembly (see the relevant section).

2. Remove the front auxiliary air supply system connection pipe (see the relevant section).

3. Remove the auxiliary drive belt (see the relevant section), having previously marked the direction of rotation on it so that the belt can be correctly oriented during installation.

4. Loosen and remove the water pump pulley mounting bolts, locking the pump shaft with a wrench. Remove the pulley and discard the bolts - they are subject to replacement (see illustrations).





5. Insert a socket with an extension rod through one of the holes in the power steering pump pulley and install it on the pump mounting bolt to lock the component. Loosen the pulley mounting bolts and remove the pulley, noting its orientation (see illustrations). Throw away the bolts - they need to be replaced.







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6. Disconnect the right cylinder head knock sensor wiring connector and detach it from the timing belt cover.

7. Unclip the covers from the front and right ends of the wiring harness support tray that sits across the timing belt cover. Disconnect the EGR valve wiring connector and move the wiring harness away from the timing belt cover, then remove the mounting bolts and remove the tray from the timing belt cover (see illustrations).







8. Loosen the mounting bolts and remove the auxiliary drive belt tensioner assembly from the right cylinder head (see illustration).





9. Unscrew the mounting bolts, then remove the outer belt cover together with the seal (see illustration).

Installation

10. Place the seal into the lid, securing it with a small amount of special glue (Opel recommends using composition 08 983 341). Install the cover onto the engine and tighten the mounting bolts to the torque specified in the Specifications.

11. Install the auxiliary drive belt tensioner and tighten the mounting bolts to the specified tightening torque Specifications.

12. Install the wiring harness support tray onto the cover and tighten the mounting bolts securely. Place the wiring in the tray, then attach the front and right covers.

13. Install the drive belt pulleys onto the water pump and power steering pump, then install the new mounting bolts. Tighten the bolts to the specified torque (see Specifications), then turn them sequentially at the corners (see Specifications). It is recommended to use a corner template for this to ensure accuracy.



14. Install the auxiliary drive belt (see the relevant section), orienting it according to the mark made before removal.

15. Install the air supply tube and accumulator (see relevant sections).

Inner lid

Removal

16. Remove the timing belt (see Chapter 7).

17. Remove the camshaft sprockets, the timing belt tensioner pulley/upper idler pulley assembly and the lower idler pulley (see Chapter 8).

18. Drain the cooling system and remove the water pump (see relevant sections).

19. Remove the mounting bolts, marking the location of the threaded stud, and remove the inner cover from the engine (see illustration).

Installation

20. Install the cover on the engine and tighten the mounting bolts and threaded stud to the specified tightening torque Specifications.

21. Install the water pump (see the relevant section).

22. Install the idler pulley, tensioner assembly, camshaft sprockets and crankshaft sprocket (see Chapter 8), then install the timing belt (Chapter 7).

23. Finally, fill the cooling system (see the relevant section).